Flexible cladding wrap, system and methods

ABSTRACT

A flexible cladding wrap for an exterior or interior wall of a building, a building wall panel, and/or a building surface is provided, the flexible cladding wrap comprising a flexible facing layer including a, preferably absorbent and more preferably porous, flexible facing substrate and powdered aggregate bonded to the facing substrate; and a flexible backing layer including a flexible backing substrate to which the facing layer is attached. A system utilising said flexible cladding wrap to create a continuous aesthetic impression of the building is also provided, in addition to methods of making and using said flexible cladding wrap.

The present invention relates to a flexible cladding wrap, a flexiblefacing layer for said wrap, and a cladding system, particularly but notnecessarily exclusively for an exterior or interior wall of a building,a building wall panel, and/or building surface using such a wrap. Theinvention furthermore relates to a method of forming such a flexiblefacing layer and cladding wrap, and to a method of creating anaesthetically pleasing façade for a building using said wrap.

Cladding for buildings, such as domestic and commercial premises, isknown, and traditionally comes in individual tiles which are laboriouslyapplied by hand to the exterior wall of the building, before then beinggrouted. However, the tiles first have to be produced, and these mayeither be moulded plastics, which are low-cost and have minimallongevity, or may be sliced from pre-manufactured brick. This lattercase is hugely wasteful, since only the outer surface is required andthus around 90% of the brick is then discarded, typically being disposedof in landfill.

Other options for cladding exist, such as plaster or render stuccomaterial. However, such outer layers on buildings are prone to crackingover a relatively short period of time due to the impact of seasonalclimate change, along with relatively rapid fading.

Furthermore, current cladding is highly repetitious, leading to aclearly unnatural finish and one which cannot be matched to thesurrounding built and historical environment.

It is known to provide panelled cladding for a building, wherein anoutwardly facing layer of the cladding can be matched to the finish ofthe building. However, rigid panels can only be integrated onto surfaceswith certain characteristics. If the external walls of a building are ina state of disrepair, for instance, it may not be possible to apply arigid panel which displays a natural finish. This can be a significantproblem for the restoration of historic buildings, where the walls maynot have entirely uniform features.

The present invention seeks to overcome all of these problems.

According to a first aspect of the invention, there is provided aflexible cladding wrap for an exterior wall of a building, the flexiblecladding wrap comprising: a flexible facing layer including an absorbentflexible facing substrate and powdered aggregate bonded to the facingsubstrate; and a flexible backing layer including a flexible backingsubstrate to which the facing layer is attached.

Preferably, the cladding wrap can be applied to and follows contouredsurfaces.

It is an object of the invention to provide a versatile façade for abuilding which has a brick- or stone-work effect, which can be readilyapplied to the exterior of said building without obviously altering theoverall appearance of the building. Given that many buildings do notnecessarily have perfectly planar exterior walls, the flexibility of thecladding wrap allows for it to be adhered to non-planar surfaces orseverely undulating surfaces which may not be able to accept panelledcladding.

The flexibility of the cladding wrap means that a variety of differentsurfaces can be repaired or renovated in an aesthetically fittingmanner, keeping the overall appearance of the building the same duringcladding application. The cladding can also be used to create a newoverall aesthetic appearance for a building, in particular a buildinghaving unusual contours.

The cladding wrap is also easily applied to a support surface, since itcan be rolled out at will, is light and easily manipulated. Theflexibility of the cladding wrap also increases its versatility whencompared with rigid cladding panels.

Using rigid cladding panels, as are known in the field of the art, it ispossible to create contours by scoring the rear faces of said rigidpanels. However, there is clearly a limit to the contouring achievableusing such panels, and some shapes will evidently not be possible tomanufacture. A flexible cladding wrap circumvents this issue.

By using preferably absorbent and/or porous substrates, the underlyingbrick or stone of the exterior wall is able to breathe through theflexible cladding wrap, whilst retaining a traditional-built appearance.This inhibits the build-up of damp or mould in the brick- or stone-work,which may otherwise occur with historic or older buildings.

Preferably, the powdered aggregate may be recycled from castoff solidinorganic material, and may be at least one of brick, stone and rock.

The powdered aggregate forms the externally facing layer of the claddingwrap, that is, the exterior, visible face. Therefore, it is preferableto use a powdered aggregate which is formed from substantially the samematerial as is already in use on the building to be clad, or on similarbuildings in the locale. The majority of buildings requiring renovationare built from brick or stone, and therefore it is advantageous toprovide a cladding wrap using at least these components in the powderedaggregate.

Preferably, the powdered aggregate may be bonded to the facing substrateusing a polymeric binding agent. Additionally or alternatively, theflexible facing layer may be bonded to the backing layer using apolymeric binding agent.

A polymeric binding agent, in particular a resin-based agent, isadvantageous for use in the cladding wrap, since it is sufficientlyadhesive to bond the layers together, whilst being sufficiently viscousto permeate through the porous layer. The binding agent is also weatherresistant, which is a primary concern for an exterior cladding.

Preferably, the flexible facing layer may be divided into tiles, thetiles being attached to the backing layer is spaced apart relationship.

It is advantageous to provide the flexible facing layer as a pluralityof tiles, fashioned to replicate the appearance of bricks or stones, forexample, to give the appearance of continuity with the existingaesthetic of the building. Typically, brickwork is arranged in apyramidal lattice-like configuration, with gaps between each brick of 1to 2 centimetres.

Preferably, the cladding wrap may further comprise a grouting layerbetween the tiles. Beneficially, this grouting layer or seam may itselfbe flexible or elastic enabling deforming without or substantiallywithout cracking or splitting.

Following on from a brickwork arrangement, it is beneficial to maintainthe aesthetic of a real brickwork wall by adding a grouting layer inbetween tiles, since this will further create the illusion that thecladding wrap is in fact a part of the existing building structure. Byusing grouting for this purpose, rather than traditional cement and/orlime compounds, the dangers of efflorescence and lime bloom aremitigated.

Preferably, the flexible facing substrate may be a woven mesh or matrix.Additionally or alternatively, the flexible backing substrate may be apolymeric mesh or matrix.

The use of a woven material, such as a cotton layer is advantageous,since it is a light and flexible material. Weather resistance isconferred to the flexible facing layer by the powdered aggregate andpolymeric binding agent, and it is therefore beneficial to provide alight substrate. A polymeric mesh may be preferable for the backingmaterial, since this will be adhered to a cladding panel or directly tothe exterior wall, and therefore strength may be of greater concern thanweight.

According to a second aspect of the invention, there is provided aflexible cladding wrap for an exterior wall of a building, the flexiblecladding wrap comprising: a facing layer including a flexible facingsubstrate and powdered aggregate bonded to the facing substrate; and aflexible backing layer including a flexible backing substrate to whichthe facing layer is attached.

Although it is beneficial that the facing layer is preferably flexible,it may be rigid.

Furthermore, it may additionally or alternatively preferable that theflexible facing substrate is absorbent. In this case, it is beneficialthat the flexible facing substrate is at least porous but may not beabsorbent. The porosity allows the powdered aggregate composition to atleast in part flow into and/or through the apertures and/or fibres in orof the facing substrate, thereby improving binding and thus integrationof the two parts.

According to a third aspect of the invention, there is provided aflexible facing layer for a flexible cladding wrap according to thefirst aspect of the invention, the flexible facing layer comprising aplurality of tiles cut from a single flexible sheet, the flexible sheetbeing formed from a powdered aggregate bonded to a woven mesh viaimpregnation with a polymeric binding agent.

It may be advantageous to provide a plurality of tiles to choose from inorder to form a flexible facing layer, in order to best match thecladding wrap to the particular building which is being renovated orrestored. This may be best achieved by creating a plurality of tiles inadvance, which may then be pooled and selected from as desired.

According to a fourth aspect of the invention, there is provided aflexible cladding wrap system for an exterior wall of a building, thesystem comprising at least one roll of flexible cladding wrap inaccordance with the first or second aspects of the invention; anadhesive for affixing the flexible cladding wrap to a supportingstructure; and a hardening agent for curing and hardening the flexiblecladding wrap once affixed.

Given that the cladding wrap is flexible, it will be appreciated that ahardening agent is or may be required in order to inhibit or preventdamage to the wrap. This would ordinarily be applied at the point ofinstallation, when the cladding wrap has been attached and moulded tothe contours of the building. The cladding wrap may be affixed directlyto the building, or to any appropriate support, using an adhesive,before the hardening agent is applied.

According to a fifth aspect of the invention, there is provided a methodof forming a flexible facing layer for a flexible cladding wrapaccording to the first aspect of the invention, the method comprisingthe steps of: a] grinding a solid inorganic material to form a powderedaggregate; b] inserting the powdered aggregate into an aggregate holdingtray or box; c] overlaying an absorbent flexible facing substrate ontothe powdered aggregate; and d] impregnating the facing substrate with apolymeric binding agent to adhere the powdered aggregate to the facingsubstrate.

Preferably, the method may further comprise a step e] of cutting theflexible facing layer into a plurality of tiles.

As stated above, it is advantageous to provide a flexible cladding wrapfor application to an exterior wall of a building. The method accordingto the fourth aspect of the invention advantageously provides a simpleway of arriving at the flexible facing layer for the flexible claddingwrap in such a way as to be able to select the aesthetic features of thecladding wrap prior to installation. The aesthetics are determined bythe powdered aggregate which is utilised in the flexible facing layer,and may be matched to the original brick or stone work either of thebuilding being treated or of the surrounding architecture.

Preferably, the method may further comprise steps: f] soaking theflexible facing layer in water; and g] reheating the flexible facinglayer, thereby creating a textured surface of the facing layer.

Whilst powdered aggregate will achieve the correct colour and generalappearance so as to appear to blend with the existing material of thebuilding, the age and therefore weathered appearance of the claddingwrap will be clearly different to the building. It is therefore possibleto simulate this weathering effect by soaking and drying the flexiblefacing layer. This process will lead to erosion of the powderedaggregate, and the flexible facing layer can be tailored to look assimilar as possible to the existing material.

According to a sixth aspect of the invention, there is provided a methodof forming a flexible cladding wrap according to the first aspect of theinvention, comprising the steps of: a] forming a flexible facing layerin accordance with the fourth aspect of the invention; b] laying out aflexible backing layer and applying a binding agent to said backinglayer; and c] overlaying the flexible facing layer onto the flexiblebacking layer, the binding agent adhering the flexible facing layer tothe flexible backing layer.

According to a seventh aspect of the invention, there is provided amethod of forming a flexible cladding wrap according to the first aspectof the invention, comprising the steps of: a] forming a tiled flexiblefacing layer in accordance with the fourth aspect of the invention; b]laying out a flexible backing layer and applying a binding agent to saidbacking layer; c] arranging the tiles of the flexible facing layer in aspaced apart configuration on the flexible backing layer, the bindingagent adhering the flexible facing layer to the flexible backing layer;d] applying a grouting layer to the spaces between the tiles; and e]applying a further polymeric binding agent to percolate through theflexible facing layer to secure the grouting.

By utilising the flexible facing layer as created according to the fifthaspect of the invention, it is therefore possible to construct aflexible cladding wrap by layering and binding several layers together.This can be done using a uniform flexible facing layer as in the fifthaspect of the invention, or by inserting tiles and grouting as describedin the sixth aspect of the invention.

Preferably, the method further comprises step: f] removing a surplus ofthe grouting following curing of the further polymeric binding agent.

Grouting is liable to leach upon application of the binding agent, andit is therefore advantageous to perform some additional aestheticrefactoring of any grouting following its application.

According to an eighth aspect of the invention, there is provided amethod of forming an aesthetically pleasing façade for an exterior wallusing a flexible cladding wrap according to the first or second aspectsof the invention, comprising the steps of: a] applying an adhesive tothe flexible backing layer of the flexible cladding wrap; b] adheringthe flexible cladding wrap to a supporting structure; and c] applying ahardening agent to cure and harden the flexible cladding wrap.

Once a flexible cladding wrap has been formed, it is therefore possibleto apply it to a building, with or without an intermediate panel, inorder to maintain an aesthetic impression. The cladding wrap must beaffixed to a support structure, be it directly to the wall, otherbuilding surface or otherwise, and then hardened in order to increaseits durability and weather resistance.

Preferably, the powdered aggregate used in the flexible cladding wrapmay be colour-matched depending on the exterior wall of the buildingand/or locality of the building.

The colour-matching of the powdered aggregate of the cladding wrap tothe exterior wall of the building and/or locality of the building meansthat the cladding wrap can be readily configured so as to blend into itssurroundings, creating a traditional built appearance despite theinclusion of non-traditional insulation materials, for instance.

According to a ninth aspect of the invention, there is provided aflexible cladding wrap for a building panel, the flexible cladding wrapcomprising: a flexible facing layer including an absorbent flexiblefacing substrate and powdered aggregate bonded to the facing substrate;and a flexible backing layer including a flexible backing substrate towhich the facing layer is attached.

According to a tenth aspect of the invention, there is provided abuilding panel comprising a panel body and a flexible cladding wrap inaccordance with the ninth aspect of the invention applied to at leastone major surface of the panel body.

Preferably, the panel body is or includes concrete. Additionally oralternatively, the building panel is a wall panel.

According to an eleventh aspect of the invention, there is provided amethod of forming a building panel in accordance with the tenth aspectof the invention, comprising the steps of: a] locating the flexiblecladding wrap in a panel mould; b] inserting flowable panel material ofthe panel body into the panel mould; c] allowing the flowable panelmaterial to cure; and d] removing the set panel body with the claddingwrap integrally formed thereto from the panel mould.

Preferably, the flowable panel material is or includes concrete.Additionally or alternatively, the method may further comprise a step e]prior to step c] of locating a further flexible cladding wrap in thepanel mould to overlie or substantially overlie the flowable panelmaterial.

Furthermore, the flexible cladding wrap may be suitable for any surfaceof a building element or structure, and therefore in accordance with atwelfth aspect of the invention, there is provided a flexible claddingwrap comprising: a flexible facing layer including an absorbent flexiblefacing substrate and powdered aggregate bonded to the facing substrate;and a flexible backing layer including a flexible backing substrate towhich the facing layer is attached. Preferably, the flexible claddingwrap is specifically adapted for facing a building surface.

According to thirteenth aspect of the invention there is provided amethod of forming a flexible facing layer for a flexible cladding wrapaccording to the first aspect of the invention, comprising the steps of:a] suspending a flexible facing substrate from a supporting framework;b] applying a wet mixture including powdered aggregate and at least onepolymer binder to the flexible facing substrate, such that the wetmixture is at least partially suspended from the flexible facingsubstrate; c] curing the wet mixture on the flexible facing substrate toadhere the two.

Forming the flexible facing layer using a wet mixture of aggregateincreases the ease of manufacture and allows for scaling of theproduction process by way of mechanical spraying or spreading.Furthermore, the wet mixture can include many different aggregates orpigments which may be combined to create any desired colour or texture.Preferably, a plurality of polymer binders is utilised for colour andtexture.

Preferably, the step of texturing the suspended wet mixture may also beincluded. This allows different textures or surface finishes to beapplied to the flexible facing layer, which can be made to matchpre-existing materials if desired.

In a beneficial arrangement, the flexible facing layer may be cut into aplurality of tiles. The tiles may be shaped so as to match any existingstonework or brickwork.

According to a fourteenth aspect of the invention there is provided amethod of forming a flexible cladding wrap in accordance with the firstaspect of the invention, comprising the steps of: a] forming a flexiblefacing layer according to the thirteenth aspect of the invention; b]laying out the flexible facing layer; c] overlaying a flexible backingsubstrate and applying a binding agent to said backing layer, thebinding agent adhering the flexible facing layer to the flexible backinglayer.

According to a fifteenth aspect of the invention, there is provided amethod of forming a flexible cladding wrap in accordance with the firstaspect of the invention, comprising the steps of: a] forming a tiledflexible facing layer in accordance with the thirteenth aspect of theinvention; b] arranging the tiles of the flexible facing layer in aspaced apart configuration; c] overlaying the flexible backing layer andapplying a binding agent through said flexible backing layer.

This allows the tiles to be arranged in any desired manner, so as tomatch a particular bond of brickwork, for instance, or to better emulatea desired appearance. Applying the binding agent through the flexiblebacking layer also ensures easy manufacture.

Preferably, a filler may be applied to spaces between the tiles. Afiller, such as a grouting composition, occludes or fills the gapsbetween the tiles and improves the aesthetics of the finished product.

More preferably, the filler may be a polymeric grouting filler. Such apolymeric grouting filler removes the need for any further binding agentand further improves flexibility of the flexible cladding wrap.

Optionally, a further polymeric binding agent may be applied topercolate through the flexible facing layer to secure the filler.

The invention will now be more particularly described, by way of exampleonly, with reference to the accompanying drawings, in which:

FIG. 1 shows a perspective representation of an embodiment of a flexiblecladding wrap according to the invention;

FIG. 2 shows a side view of the flexible cladding wrap of FIG. 1;

FIG. 3 shows the flexible cladding wrap of FIG. 1 in a rolledconfiguration;

FIG. 4 is a diagrammatic representation of a method of forming aflexible facing layer of the flexible cladding wrap, in accordance withthe fifth aspect of the invention;

FIG. 5 is a diagrammatic representation of preferable further steps ofthe method, as shown in FIG. 4;

FIG. 6 shows a perspective view of a preferred arrangement of tiles of aflexible facing layer, in accordance with the third aspect of theinvention;

FIG. 7 is a diagrammatic representation of a method of forming aflexible cladding wrap, in accordance with the sixth aspect of theinvention;

FIG. 8 shows a perspective view of a preferred arrangement of anassembly of a flexible backing layer and a flexible facing layer of theflexible cladding wrap for use in the method as shown in FIG. 7;

FIG. 9 shows a perspective view of a flexible cladding wrap formed via amethod in accordance with the seventh aspect of the invention;

FIG. 10 shows a perspective view of a wet mixture being applied to aflexible facing substrate to form a flexible or non-flexible facinglayer, in accordance with the invention;

FIG. 11 shows a perspective view of the flexible facing layer of FIG.10, with a backing surface applied, being inverted;

FIG. 12 shows a perspective view of the inverted flexible facing layerof FIGS. 10 and 11 being cured by a curing means;

FIG. 13 shows a perspective view of the flexible facing layer of FIG. 12cut into separate brick-like tiles, ready for further processing;

FIG. 14 shows a perspective view of the tiles of FIG. 13 being mountedto a flexible backing layer, in accordance with the invention; and

FIG. 15 shows a perspective view of the flexible cladding wrap of FIG.14 mounted to a wall, with a grouting layer between tiles.

Referring to the accompanying drawings and particularly initially toFIGS. 1 to 3, there is shown a flexible cladding wrap which isspecifically adapted for facing a building surface and, in thisembodiment, suitable for an outer surface of an exterior wall of abuilding, indicated globally at 10. Although an exterior wall surface issuggested, the flexible cladding wrap may also be utilised to face aninternal wall surface. The cladding wrap 10 comprises two layers whichare adhered to one another; a flexible backing layer 12 which forms awall-facing surface 14 of the cladding wrap 10, and a flexible facinglayer 16, which forms an external surface 18 of the cladding wrap 10when installed. In this embodiment, the facing layer 16 is flexible.However, in other embodiments, the facing layer 16 may be rigid orsubstantially rigid once cured. Typically, the cladding wrap 10 willhave a thickness of, but not necessarily limited to, the order of 1 to15 mm, in order to retain the flexibility of the component layers 12,16.

The flexible backing layer 12 comprises a flexible backing substrate 20.This substrate 20 is at least partially porous, typically being apolymeric matrix, for instance, a polypropylene mesh.

The flexible facing layer 16 includes a, preferably absorbent and morepreferably porous, flexible facing substrate 22 and a powdered aggregate24 which is bonded to the facing substrate 22. The facing substrate 22is preferably a woven material, such as an absorbent cotton mesh. Themost important properties of said substrate 22 are its flexibility andthat it is porous, thereby allowing percolation of a binding agenttherethrough.

The flexible facing layer 16 will generally take the form of a pluralityof tiles 26 arranged in sequence to resemble the external appearance ofthe wall to which the cladding wrap 10 will be affixed.

The powdered aggregate 24 is formed from recycled castoff solidinorganic material, typically comprising at least one of brick, stone orrock. Said material will be chosen primarily for its aesthetic appeal,so as to match the external appearance of the building to which it isbeing affixed. For example, brick and/or sandstone aggregates might becommon choices for the aggregate 24.

To achieve the desired finish, thereby allowing matching or substantialmatching to the building's local, historic or architectural environmentand/or its original finish, the powdered aggregate 24 may becolour-matched using a system similar to that used for colour matchingpaint or other liquid coating products. In this way, during formation ofthe powdered aggregate 24, the correct colour and texture of materialscan be chosen to produce the required finish.

Additionally, more than one different type of powdered aggregate 24 maybe utilised, thereby enabling a base colour or appearance with patches28 of weathering or other random anomalies appearing thereon, such asin-grained dirt or other particulate debris or detritus which ordinarilybuild up through years of standing in the open environment and beingsubjected to all kinds of weather.

Prior to curing the powdered aggregate 24, mechanical marking may alsobe utilised to enhance realism. For example, striation marks may beapplied via a scraping device to impart peaks and troughs across anouter surface replicating slicing by a mechanical cutter.

The aggregate 24 is bonded to the facing substrate 22 using a polymericbinding agent 30, typically a resinous compound. The backing and facinglayers 12, 16 may also be bound together using a polymeric binding agent32. See FIG. 7. This may or may not be the same compound as used to bondthe aggregate 24 to the facing substrate 22.

If the flexible facing layer 16 is provided as spaced-apart tiles 26, afiller, such as a grouting layer 34, will also be provided in the spaces36 between the tiles 26. Said grouting layer 34 is bonded to theflexible facing layer 16 again using a polymeric binding agent, whichwill typically be the same compound as is used to bind the other layerstogether. The grouting layer 34 may be flexible and/or elastic, toaccommodate in use flexion of the facing layer 16.

To create such a flexible cladding wrap 10, by way of one non-limitingexample only, there is provided an aggregate holding device 38, shown inFIG. 4, being a structure having a rectangular upper surface 40 havingan upwardly projecting perimeter wall 42 defining a retaining area forthe powdered aggregate 24, and a plurality of supporting legs 44 toelevate the upper surface 40 from ground level. The upper portion of theaggregate holding device 38 may be removed from the supporting legs 44to provide an aggregate holding tray or box 46, from which a finishedcladding wrap 10 can be easily removed.

By way of indication, the aggregate holding tray 46 has typicaldimensions of 6 foot (1.83 metres) by 3 foot (0.91 metres) by 8 inches(0.2 metre), and a generated cladding wrap 10 therefrom will have anarea of 6 foot (1.83 metres) by 3 foot (0.91 metres), typically having athickness of up to around 0.625 inches (0.016 metre). These dimensionsare for illustrative purposes only, and a said cladding wrap of anydimension can feasibly be made.

The powdered aggregate 24 is placed into the aggregate holding tray 46and dispersed so as to form an even layer on the upper surface 40. Overthe aggregate 24 is then positioned the flexible facing substrate 22,cut to size to fit into the aggregate holding tray 46, and then thepolymeric binding agent 30 is applied over the flexible facing substrate22.

The polymeric binding agent 30 will percolate through the porous facingsubstrate 22, soaking through and penetrating the powdered aggregate 24.Heat and air are then applied to the assembly, which will form theflexible facing layer 16, thereby curing the polymeric binding agent 30and binding the powdered aggregate 24 to the flexible facing substrate22.

Upon curing, a flexible facing layer 16 is thus formed. This will havethe aesthetic appearance of whichever material was used to form thepowdered aggregate 24. Typically, buildings do not have a uniformexternal appearance, particularly historical buildings, and as such, theflexible facing layer 16 may be cut into tiles 26 to suit the externalappearance of the particular building. As shown in FIG. 5, this may be aseries of tiles which have regular dimensions, and in the presentembodiment of the invention, said tiles 26 are designed to have theappearance of bricks.

At this stage, it is advisable to perform any additional work to thetiles 26 as is necessary to improve their aesthetic appearance so as tonaturally blend with the exterior wall of the building to which thecladding wrap 10 is to be applied. Such work could be, but is notlimited to, smoothing or weathering the surfaces of the tiles 26,reshaping particular tiles 26 in order to match the present exteriorsurface of the building, or adding surface detail to each or particulartiles 26.

To achieve a weathered look, each tile 26 may be soaked in water andreheated to create a natural surface finish. This could alternatively beperformed on the flexible facing layer 16 prior to cutting intoindividual tiles 26.

Once a desired look or appearance of the tiles 26 has been achieved, theflexible cladding wrap 10 can be formed. This is achieved by attachingthe flexible facing layer 16 to the flexible backing layer 12.

The flexible facing layer 16 is first arranged in the aggregate holdingdevice 38. If the flexible facing layer 16 is a unitary sheet, then thisis straightforward, but if it has been divided into tiles 26, then thetiles 26 must be arranged in the desired configuration, such as thatshown in FIG. 6. For instance, if replicating brickwork, this mayinvolve stacking the tiles 26 in pyramidally stacked layers, with evenand odd layers 48, 50 being horizontally offset to one another by thelength of half or 50% of a tile 26.

Once the desired configuration is achieved, the flexible backingsubstrate 20 is overlain, and the polymeric binding agent 32 is appliedto the assembly, shown in FIGS. 7 and 8. Again, heat and air areapplied, curing the polymeric binding agent 32 and secured the backingand facing layers 12, 16 to one another.

If a grouting layer 34 is to be included, then a similar process needsto occur. The grouting layer 34 is applied to the spaces 36 between thetiles 26, and a polymeric binding agent is applied, heated, and allowedto cure, thereby fixing the grouting 34 into position. Excess grouting34 may then be removed from the cladding wrap 10, for instance, using anabrasive means such as sandpaper. A flexible cladding wrap 10 formedwith a grouting layer 34 is shown in FIG. 9.

Evidently, it is entirely possible to perform the above steps in asingle procedure; the tiles 26 can be arranged and the grouting layer 34simultaneously applied, before applying a single polymeric binding agent32. Alternatively, the grouting layer 34 could be applied subsequentlyto the application of the polymeric binding agent 32, but before it hascured.

Having created the flexible cladding wrap 10, it can therefore be usedin a variety of applications which utilise its flexibility. Purely froma transportation perspective, the flexible cladding wrap 10 is capableof being rolled up into a convenient tube-like configuration 100, asshown in FIG. 3. This allows the cladding wrap 10 to be transported andapplied in a manner akin to the application of wallpaper.

During installation of the flexible cladding wrap 10, the roll 100 canbe unfurled and cut to size. An adhesive can then be applied to thewall-facing surface 14 or other support to which the cladding wrap 10 isto be affixed, and then the cladding wrap 10 can be installed. Thecladding wrap 10 is smoothed so as to follow the contours of itssupport, eliminating any air pockets which may have formed between thesupport and the wall-facing surface 14 during installation, and theadhesive allowed to dry.

At this stage, the cladding wrap 10 is therefore affixed in position,but is still relatively fragile. As such, a hardening agent is or may beapplied to the external surface 18 of the cladding wrap 10, whichimpregnates the flexible facing layer 16; hardening and increasing theweather-resistance of the cladding wrap 10. The hardening agent isallowed to set, completing the installation process.

In this case, the flexible cladding wrap is as described above, and inthis example is provided in the mould of a panel body of the buildingwall panel, with the rearmost surface facing upwards. Flowable panelmaterial, which may be or include concrete and which forms the panelbody, is then inserted into the mould to overlie the flexible claddingwrap. Once cured or set, the panel body can be removed with the flexiblecladding panel bonded monolithically or integrally formed therewith toface one major surface.

Optionally, a further flexible cladding wrap may be incorporated bybeing inserted into the mould to overlie the flowable panel materialonce poured. In this case, once set and removed, the panel body is facedon its two major surfaces with the integrated flexible cladding wraps.

A second method of manufacturing a flexible cladding wrap 110 isdepicted in FIGS. 10 to 15. In each of these Figures, similar or likefeatures to those of the preceding embodiments are given similar or likereferences. Referring firstly to FIG. 10, a flexible facing substrate122 may be hung or stretched over a supporting framework 152. Thesupporting framework 152 depicted comprises four wooden frame elements152 a, arranged to form the substantially rectangular supportingframework 152. The flexible facing substrate 122, which may preferablycomprise at least polypropylene mesh, is attachable to the supportingframework 152 such that the flexible facing substrate 122 is held inplace during a portion of the manufacturing process, but may be removedfrom the supporting framework 152 once it is no longer necessary.Attachments 154, which in this case are nails, may include staples,and/or other such attachment means in place of, or in addition to,nails.

A wet mixture 156 is then applied to the flexible facing substrate 122.The wet mixture 156 comprises one or a variety of wet and dry powdered,preferably recycled, aggregates mixed with polymer binders, the choiceof which may be varied to alter the colour and texture of the mixture156. The mixture 156 may also include one or more liquid pigments forrecreation of different colours. This wet mixture 156 may be applied tothe flexible facing substrate 122 by way of spreading, pouring,spraying, or other such application method, to create a flexible facinglayer 116.

For additional benefits, one or more geopolymers may be used, which aregenerally for example alumino-silicates. These geopolymers lower thecarbon-footprint of the material manufacture due to their manufacturefrom minimally processed natural materials or industrial by-products.

The mixture 156 may beneficially have fire-retardant properties, bepermeable, and/or be water repellent, each of which may increase thelongevity of the resulting flexible cladding wrap 110. The mixture 156may also be formulated to match old or new brick and stone stock, whichallows the cladding material or wrap 110 to be used in addition to, orin place of, naturally occurring brick and stonework, for enhancedaesthetics.

The application of the wet mixture 156 to the flexible facing substrate122 forces at least a portion of the wet mixture 156 through theflexible facing substrate 122, forming an at least partially suspendedmixture 158. The suspended mixture 158 may then be textured or shaped byuse of a mould, or other instrument, in situ, to produce the desiredsurface finish. Moulding or texturing enables the flexible cladding wrap110 to even further replicate a natural finish, which may be preferable.

A holding plate 160 may then be placed over the top of the flexiblefacing layer 116, as shown in FIG. 11, before the flexible facing layer116, which is flexible at this stage in the process, is inverted readyfor curing, with the previously suspended mixture 158 now exposed. FIG.12 depicts the flexible facing layer 116 being exposed to a curingmeans, which in this case is one or more infrared heat lamps 162. Theinfrared heat lamp 162 results in removal of moisture from or throughthe flexible facing substrate 122 in order to harden, or cure, theflexible facing layer 116.

Once fully cured, the flexible facing layer 116 may be cut or otherwiseformed into individual tiles 126. Depending on the desired finishedproduct, the tiles 126 may be rectangular in order to simulate thenormal shape of a clay brick, or any other shape if it is desired toemulate differently-shaped bricks, stones or other such buildingmaterials.

The tiles 126 may then be laid out in a desired arrangement on asurface, with their textured surface 164 facing down, in order that aflexible backing layer 112 may be overlaid. The flexible backing layer112 comprises a flexible backing substrate 120 which in this case isperforated. A suitable binding agent, such as a polymer glue oradhesive, is then applied through the flexible backing layer 112 andcured in order to bond the facing layer 116 to the backing layer 112,resulting in the formation of the flexible cladding wrap 110. Thedesired arrangement may be any formation or bond including, but notlimited to, Flemish bond, English bond, or traditional stretcher bond.The particular bond or formation used will be dependent on the desiredaesthetics or whether the flexible cladding wrap 110 is required tomatch previous brick- or stone-work.

The flexible cladding wrap 110 may then be installed on a wall or othersurface by use of a strong adhesive, such as brick adhesive. It isadvantageous for this adhesive to also act as a grouting layer or filler134, however grouting 134 or other filler may be otherwise applied tothe flexible cladding wrap 110 as a separate element, during eithermanufacture or installation. The grouting layer 134 or adhesive, whichis preferably a polymer acrylic adhesive or grout 134, such thatflexibility may be retained, may be applied onto the flexible backingsubstrate 120, creating a seamless finish. One example of a suitableadhesive is Mapei® ‘Fix and Grout’, available from Mapei UK Ltd of MapeiHouse, Steel Park Road, Halesowen, West Midlands, B62 8HD, UK.

It will be appreciated that the form of the support to which theflexible cladding wrap is applied is entirely context dependent. Undercertain circumstances, it may be preferable to apply the cladding wrapdirectly to a wall of the building; under others, the cladding wrap maybe more appropriately affixed to a panel or façade prior toinstallation. The present invention does not seek to discriminatebetween either of these methods of use.

Furthermore, should the cladding wrap be applied to a panel or façade,it is possible to integrate extra materials in between the support andthe cladding wrap, for instance, to improve the thermally insulativeproperties of the system. One or more further dedicated or specificthermally insulative boards, for example, formed of mineral wool orpolystyrene may be provided at a rear of the backing layer, usingsuitable fastening means such as bonding.

In addition, whilst the backing layer and facing layer are main layersof the flexible cladding wrap, additional layers may be utilised betweenthe two. These layers may include further protective layers to provideenhanced protection against the elements, or may otherwise give, forexample, better thermally insulative properties than the backing andfacing layers when used alone.

The list of possible materials for powdered aggregate detailed above isnon-exhaustive, and will also be context dependent. The powderedaggregate will be specifically chosen so as to match the material usedin construction of the building, or buildings in the locale. Theaesthetic effect is the important feature, rather than any particularstructural property of the base material.

The production process of the flexible cladding wrap can be automated ona production line, or can be performed manually. It may for instance bedesirable to mass-produce a majority of tiles, but to manually create aminority of tiles in order to suit the appearance of a particularbuilding.

It will also be appreciated that the flexible cladding wrap may beutilised for covering or overlying other or any suitable buildingsurface. As such, the flexible cladding wrap may be provided on abuilding wall panel so as to be integral therewith. In particular,having the flexible cladding wrap integrally formed as part of a wallpanel, and more particularly as part of a, preferably lightweightstructural, concrete wall panel, is beneficial. Lightweight structuralconcrete wall panels are well known in the field, and therefore furtherdetailed description will be omitted.

Although the flexible facing substrate is absorbent in the aboveembodiments, it may be beneficial that the flexible facing substrate isat least porous but may not be absorbent. The porosity allows thepowdered aggregate composition to at least in part flow into and/orthrough the apertures and/or fibres in or of the facing substrate,thereby improving binding and thus integration of the two parts.

Additionally or alternatively, the facing layer may be rigid instead offlexible, but this may potentially impact the conformance of the wrap toa more uneven surface.

In the above two alternatives, one or more features of the precedingembodiments may be utilised alone or in any combination, as required.

Whilst described as two separate processes, it is foreseen that thesteps of the methods of creating a flexible facing layer and flexiblecladding wrap may be used in any combination, where feasible, in orderto create hybrid processes or methods.

It is therefore possible to provide a flexible cladding wrap for anexternal wall of a building, a building wall panel, or any suitablebuilding surface such as an internal wall or surface, floor surfaceand/or ceiling surface, and which is able to provide aestheticcontinuity between the existing wall of the building and the claddingwrap.

By providing a flexible cladding wrap, the effect can therefore beprovided to numerous surfaces which previously would not have beencapable of accepting panelled cladding due to the unusual contouring ofthe external wall of the building.

The method in which the flexible wrap is created also allows for theformation of tile effects that are capable of mimicking brick- orstone-work, whilst still retaining the necessary flexibility.

The words ‘comprises/comprising’ and the words ‘having/including’ whenused herein with reference to the present invention are used to specifythe presence of stated features, integers, steps or components, but donot preclude the presence or addition of one or more other features,integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the invention which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable sub-combination.

The embodiments described above are provided by way of examples only,and various other modifications will be apparent to persons skilled inthe field without departing from the scope of the invention as definedby the appended claims.

1. A flexible facing layer for altering or creating the appearance of anexterior wall of a building, the flexible facing layer comprising: aflexible facing substrate; and a powdered aggregate being at least inpart solid material bonded to the facing substrate by way of a polymericbinding agent, thereby forming a visible tiled layer for the creation ofa brick- or stone-work effect, the polymeric binding agent being heatand air curable, so that the layer remains porous and flexible.
 2. Theflexible facing layer as claimed in claim 1, further comprising agrouting layer bonded to the flexible facing substrate by the first saidor a second polymeric binding agent between tiles of the tiled layer. 3.The flexible facing layer as claimed in claim 2, wherein the groutinglayer is flexible and/or elastic.
 4. The flexible facing layer asclaimed in claim 1, wherein the powdered aggregate is at least one ofbrick and stone.
 5. The flexible facing layer as claimed in claim 1,wherein the powdered aggregate is recycled from solid inorganicmaterial.
 6. The flexible facing layer as claimed in claim 1, whereinmore than one different type of said powdered aggregate is provided. 7.The flexible facing layer as claimed claim 1, wherein the flexiblefacing substrate is a woven mesh or matrix.
 8. The flexible facing layeras claimed in claim 1, wherein the powdered aggregate and/or thepolymeric binding agent comprises one or more geopolymers.
 9. Theflexible facing layer as claimed in claim 1, wherein the powderedaggregate and/or the polymeric binding agent comprises one or morefire-retardant additives.
 10. The flexible facing layer as claimed inclaim 1, wherein the polymeric binding agent is a resinous compound. 11.The flexible facing layer as claimed in claim 1, wherein the visibletiled layer has a textured surface.
 12. A building wall flexiblecladding wrap for an exterior wall of a building, the building wallflexible cladding wrap comprising: a flexible facing layer as claimed inclaim 1 substantially forming a visible layer of the cladding wrap tocreate a brick- or stone-work effect; and a flexible backing layerincluding a flexible backing substrate to which the facing layer isattached.
 13. The building wall flexible cladding wrap as claimed inclaim 12, wherein the cladding wrap can be applied to and followcontoured surfaces in use.
 14. The building wall flexible cladding wrapas claimed in claim 12, wherein the flexible facing layer is bonded tothe backing layer using the polymeric binding agent.
 15. The buildingwall flexible cladding wrap as claimed in claim 12, wherein the flexiblebacking substrate is a polymeric mesh or matrix.
 16. The building wallflexible cladding wrap as claimed in claim 12, provided in the form of aroll.
 17. The building wall flexible cladding wrap as claimed in claim12, further comprising a hardening agent applied to the flexible facinglayer.
 18. The building wall flexible cladding wrap as claimed in claim12, further comprising at least one additional layer positioned betweenthe flexible facing layer and the flexible backing layer.
 19. A buildingpanel comprising a panel body and a building wall flexible cladding wrapas claimed in claim 12 applied to at least one major surface of thepanel body.
 20. The building panel as claimed in claim 19, wherein thepanel body is or includes concrete.